Electroluminescent Element Within Laminate

ABSTRACT

A laminate having an electroluminescent element disposed within the laminate is disclosed. The laminate includes a first paper layer having at least first and second vias through the first paper layer; a first electrically-conductive layer comprising an electrically-conductive material, the first electrically-conductive layer being disposed over the first paper layer; a dielectric layer disposed over the first electrically-conductive layer; a light emissive layer comprising an electroluminescent material, the light emissive layer being disposed over the dielectric layer; a second electrically-conductive layer comprising a translucent electrically-conductive material, the second electrically-conductive layer being disposed over the light emissive layer; an insulating layer disposed over the second electrically-conductive layer. The first paper layer and the insulating layer encapsulate the first electrically-conductive layer, the dielectric layer, the light emissive layer, and the second electrically-conductive layer.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.15/488,437, filed Apr. 14, 2017, which is incorporated herein byreference in its entirety and made a part hereof.

BACKGROUND OF THE INVENTION

Decorative laminates have been used as surfacing materials for manyyears, in both commercial and residential applications, where pleasingaesthetic effects in conjunction with desired functional behavior (suchas superior wear, heat and stain resistance, cleanability and cost) arepreferred. Typical applications have historically included furniture,kitchen countertops, table tops, store fixtures, bathroom vanity tops,cabinets, wall paneling, office partitions, and the like.

Laminates are useful as surfacing materials, including as decorativesurfaces, in many situations due to their combination of desirablequalities (e.g., superior wear, heat and stain resistance, cleanability,and cost). Laminate surfaces are composed of discrete layers, such aslayers of resin-impregnated kraft paper that are pressed to form thelaminate. One conventional decorative laminate is made by stacking threesheets of treated kraft paper (e.g., three sheets of phenol-formaldehyderesin-impregnated kraft paper), dry decorative paper (e.g., a printsheet), and a sheet of treated overlay paper (e.g. melamine-formaldehyderesin-impregnated tissue paper or acrylic resin-impregnated tissuepaper), one on top of another and then bonded together with heat andpressure.

A high-pressure laminate process (HPL) is an irreversible thermalprocess wherein resin-impregnated sheets of kraft paper undergo asimultaneous pressing and heating process at relatively high levels ofheat and pressure, such as temperatures greater than or equal to 125° C.and at least 5 mega Pascals (MPa) of pressure, typically for a presscycle of 30-50 minutes. An HPL process contrasts with low pressurelaminate processes (LPL) that is conducted at pressures of less than 5.0MPa, typically between 2-3 MPa.

SUMMARY OF THE DISCLOSURE

This summary is provided to introduce a selection of concepts in asimplified form that are further described in the Detailed Descriptions.This summary is not intended to identify key features or essentialfeatures of the claimed subject matter, nor is it intended to be used tolimit the scope of the claimed subject matter.

A laminate with an electrical element (e.g., an electroluminescentelement) embedded within the laminate comprising a first paper layerhaving at least first and second vias through the first paper layer, afirst electrically-conductive layer comprising anelectrically-conductive material, the first electrically-conductivelayer being disposed over the first paper layer, a dielectric layerdisposed over the first electrically-conductive layer, a light emissivelayer comprising an electroluminescent material, the light emissivelayer being disposed over the dielectric layer, a secondelectrically-conductive layer comprising a translucentelectrically-conductive material, the second electrically-conductivelayer being disposed over the light emissive layer, an insulating layerdisposed over the second electrically-conductive layer, wherein thefirst paper layer and the insulating layer encapsulate the firstelectrically-conductive layer, the dielectric layer, the light emissivelayer, and the second electrically-conductive layer within the laminate,and wherein the first electrically-conductive layer is electricallycoupled to the first via and the second electrically-conductive layer iselectrically coupled to the second via, the first and second viasincluding the electrically-conductive material therein is disclosed.

A method for manufacturing a laminate with an electrical element (e.g.,an electroluminescent element) embedded within the laminate comprisingforming at least first and second vias through a first paper layer,disposing a first electrically-conductive layer over the first paperlayer, wherein the first electrically-conductive layer comprises anelectrically-conductive material, disposing a dielectric layer over thefirst electrically-conductive layer, disposing a light emissive layerover the dielectric layer, wherein the light emissive layer comprises anelectroluminescent material, disposing a second electrically-conductivelayer over the light emissive layer, wherein the secondelectrically-conductive layer comprises a translucentelectrically-conductive material, disposing an insulating layer over thesecond electrically-conductive layer, and compressing the first paperlayer, the first electrically-conductive layer, the dielectric layer,the light emissive layer, the second electrically-conductive layer, andthe filled first and second vias according to a lamination process,thereby electrically connecting a first via to the firstelectrically-conductive layer and a second via to the secondelectrically-conductive layer and encapsulating the first paper layer,the first electrically-conductive layer, the dielectric layer, the lightemissive layer, and the second electrically-conductive layer within thelaminate is disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an example of a laminate surfacingmaterial integrated into a countertop with an electroluminescent elementdisposed on multiple layers within the laminate structure;

FIG. 2 shows an example of a laminate having an electroluminescentelement disposed within the laminate structure;

FIG. 3 generally illustrates example operations for forming anelectrical via between layers in a laminate using a masking technique;

FIG. 4 generally illustrates example operations for forming anelectrical via between layers in a laminate using a hole cuttingtechnique;

FIG. 5 shows a flowchart for manufacturing a laminate having anelectroluminescent element disposed on multiple layers within thelaminate.

DETAILED DESCRIPTION

A laminate with an electrical element (e.g., an electroluminescentelement) embedded within the laminate comprising a first paper layerhaving at least first and second vias through the first paper layer, afirst electrically-conductive layer comprising anelectrically-conductive material, the first electrically-conductivelayer being disposed over the first paper layer, a dielectric layerdisposed over the first electrically-conductive layer, a light emissivelayer comprising an electroluminescent material, the light emissivelayer being disposed over the dielectric layer, a secondelectrically-conductive layer comprising a translucentelectrically-conductive material, the second electrically-conductivelayer being disposed over the light emissive layer, and an insulatinglayer disposed over the second electrically-conductive layer isdisclosed. In embodiments, the first paper layer and the insulatinglayer may encapsulate the first electrically-conductive layer, thedielectric layer, the light emissive layer, and the secondelectrically-conductive layer within the laminate. The firstelectrically-conductive layer may be electrically coupled to the firstvia and the second electrically-conductive layer may be electricallycoupled to the second via, the first and second vias including theelectrically-conductive material therein, the first via makingelectrical contact with the first electrically-conductive layer and thesecond via making electrical contact with the secondelectrically-conductive layer. In embodiments, the insulating layer maycomprise a decorative layer. For example, the insulating layer maycomprise a resin-impregnated decorative layer. As another example, theinsulating layer may comprise a treated overlay paper layer. When theinsulating layer comprises a treated overlay paper layer, the laminatemay further comprise a dry or untreated decorative paper (also known asa print sheet) between the treated overlay paper layer and the secondpaper layer. Of course, the laminate may also comprise glue film layers,for example when untreated kraft paper layers are included as furtherdescribed below.

Generally, as used herein, a “decorative layer” is a visible outer layerin the (final, assembled) laminate. A decorative layer may havedecorative colors and/or designs. Of course, as mentioned above, anoverlay layer may be disposed above a decorative layer provided that thedecorative layer is at least partially visible through the overlaylayer.

A laminate surfacing material with the electrical element arranged ondifferent paper layers (e.g., resin-impregnated paper layers) of thelaminate surfacing material has particularly useful characteristics,including: the ability to add more electrical elements in aspace-efficient manner by providing additional electrically-conductivematerials on different layers of the laminate; favorableheat-dissipation properties due to the lack of insulating air inside thelaminate and optional use of fillers with high heat transfercoefficients (e.g., ceramics such as aluminum nitride, aluminum oxide,boron nitride, and combinations thereof) in the resin formulations usedto prepare the resin-impregnated paper layers such that heat transferaway from the electrical element is enhanced, effectively turning thelaminate surfacing material into an efficient heat sink and facilitatingthe utilization of the electrical element; unexpected and surprisingelectrical conductivity of the electrically-conductive material used toprovide the electrical element even after undergoing an HPL process; andthe ability to be integrated into almost any surface (e.g., countertop,wall, piece of furniture, door, window frame, interior of a vehicle,etc.). The resin-impregnated paper layers also provide a durableenclosure for the electrical element.

The electrical element may be formed by providing (e.g., disposing) anelectrically-conductive material (e.g., electrically-conductive ink)onto paper layers (e.g., kraft paper, tissue paper, etc.) having viaholes cut through the paper layers for electrically couplingsub-elements or layers of the electrical element. Disposing (e.g.,printing) the electrically-conductive material onto paper allows thepaper fibers to act as reinforcements for various layers of theelectrical element created from the electrically-conductive material,preventing breakage of the electrical element due to shrinkage orexpansion due to various environmental conditions. The layers of theelectrical element may be stacked and encapsulated between discretepaper layers using a lamination process. While low pressure laminationmay be used to prepare laminates according to the disclosure, a highpressure lamination process including a re-cooling stage (referred toherein as “high pressure lamination process”) is preferred.

As described herein, the electrical element is “encapsulated” orsubstantially protected by providing the electrically-conductivematerial for the electrical element on a first paper layer and disposingan insulating layer above the electrically-conductive material such thatthe electrical element is at least partially protected or shielded fromambient atmosphere by the overlying layer.

It has been found that when laminates are exposed to the heat andpressure in the high pressure lamination process, the risk of breakingor delamination of the sub-elements or layers of the electrical elementis greatly reduced. The high pressure lamination process allows theelectrical element to have electrically-conductive tracks havingimproved track densification, which achieves surprisingly higherconductivities than through other conventional manufacturing techniques.Initiating the high pressure lamination process after stacking thelayers of the electrical element between the paper layers collectivelycures layers included in the laminate simultaneously, which eliminatesthe conventional need for using an adhesive to adhere together layersthat have individually been fully cured. The high pressure laminationprocess allows for accurate control of temperature and pressure (e.g.,heating and cooling cycles) in order to control the rate of dimensionalchange of layers and surprisingly leads to enhanced electricalconductivity of the electrically-conductive material used in thelaminate process.

Various embodiments of the present disclosure are methods for preparinglaminates with the electrical element embedded within the laminate. Themethods include forming via holes through paper layers, disposing (e.g.,inkjet printing, flexographic printing, gravure printing, screenprinting, extrusion printing, and the like) sub-elements or layers ofthe electrical element with electrically-conductive material onto thepaper layers, and providing vias through the paper layers at selectedvia hole locations with an electrically-conductive material toelectrically couple various layers of the electrical element. Factors indetermining the selected locations may include efficient layout design,avoiding shorting layers of the electrical element, etc. The layers ofthe electrical element may be stacked and encapsulated between the paperlayers by subjecting the laminate to the high pressure laminationprocess, which surprisingly results in advantageously enhanceddensification of the electrically-conductive material and excellentconductivity. It should be noted that the same electrically-conductivematerial may be used for the electrical element and the vias, butdifferent electrically-conductive materials may also be used.

In one preferred embodiment, a method of making a laminated surfacematerial comprises providing at least an first untreated kraft paperlayer, a glue film layer, and an insulating layer; forming an electricalelement comprising an electrically-conductive material, the electricalelement further comprising a first electrically-conductive layer, adielectric layer disposed over the first electrically-conductive layer,a light emissive layer disposed over the dielectric layer, and a secondelectrically-conductive layer disposed over the light emissive layerarranged on the first untreated kraft paper layer; arranging a stackcomprising at least the first untreated kraft paper layer, the glue filmlayer, and the insulating layer such that the insulating layer isdisposed above the glue film layer; compressing the stack according to alamination process. Typically, the stack includes an additional gluefilm layer disposed below the first untreated kraft paper layer so as toallow a sufficient amount of resin to saturate the laminate during alamination process, in order to provide sufficient mechanical strengthto the final formed laminate. By providing the firstelectrically-conductive layer on untreated kraft paper, significantlyimproved alignment of holes formed in the stack can be achieved thanwhen the first electrically-conductive layer is disposed onresin-impregnated paper layers. A glue film layer as used herein is alayer having a sufficient amount of thermoset resin to saturate anadjacent untreated paper layer (e.g., a decorative layer or a kraftpaper layer). Typically, a glue film layer will comprise a paper layerhaving between 30-80 percent by weight of a thermoset resin. Preferably,the thermoset resin of the glue film comprises phenol-formaldehyderesin.

Thus, a preferred laminated surface material comprises a stackcomprising at least an first untreated kraft paper layer, a glue filmlayer, and an insulating layer such that the insulating layer isdisposed above the glue film layer; an electrical element comprising anelectrically-conductive material, the electrical element furthercomprising a first electrically-conductive layer, a dielectric layerdisposed over the first electrically-conductive layer, a light emissivelayer disposed over the dielectric layer, and a secondelectrically-conductive layer disposed over the light emissive layerarranged on the first untreated kraft paper layer. Typically, the stackincludes an additional glue film layer disposed below the firstuntreated kraft paper layer so as to allow a sufficient amount of resinto saturate the laminate during a lamination process, in order toprovide sufficient mechanical strength to the final formed laminate.

Electrically-conductive materials suitable for use in accordance withthe various embodiments of the present disclosure include any materialwhich can be disposed upon paper, such as resin-impregnated paper, andwhich may be electrically electrically-conductive. In some embodiments,the composition of the electrically-conductive material includes: (i) aparticulate, electrically-conductive material; (ii) a binder; andoptionally (iii) a microcrystalline cellulose component.

The particulate, electrically-conductive material may include any one ofmetals, alloys, electrically-conductive carbons (e.g.,electrically-conductive allotropes of carbon, graphites),electrically-conductive polymers (e.g., polypyrrole),electrically-conductive metallized polymers (e.g., metallizedpolyethylene terephthalates), and combinations thereof. In a preferredaspect, the particulate electrically-conductive material comprisessilver and/or silver alloys. Electrically-conductive ink compositionswhich may be disposed to provide electrically-conductive material on apaper layer and are thus suitable for use in various embodiments of thepresent disclosure typically include particles comprising metal, metalalloys, electrically-conductive carbon, or other electrically-conductivematerials such as polymers, in a carrier medium which may include otherpolymers, solvents and additives. Various known methodologies such asinkjet printing, screen printing, flexographic printing, gravureprinting, or extrusion printing may be used to dispose theelectrically-conductive ink compositions on the substrate.

One embodiment of an electrically-conductive ink composition suitablefor providing the particulate electrically-conductive material is anelectrically-conductive ink composition comprising: (i) a particulate,electrically-conductive material; (ii) a carrier liquid; (iii) a polymerbinder; and (iv) a microcrystalline cellulose component. Anotherembodiment of an electrically-conductive ink composition suitable forproviding the particulate electrically-conductive material is anelectrically-conductive ink composition comprising: (i) a particulate,electrically-conductive material; (ii) a carrier liquid; (iii) a polymerbinder; and (iv) a microcrystalline cellulose component; wherein theparticulate, electrically-conductive material comprises a componentselected from the group consisting of silver and silver alloys; andwherein the microcrystalline cellulose component is present in an amountof from about 0.05% to about 10% by weight based on the composition andhas an average particle size of from about 20 to about 100 μm. Incertain embodiments of the disclosure, the microcrystalline cellulosecomponent may include two or more microcrystalline celluloses havingdifferent average particle sizes. As noted above, disposing methods suchas inkjet printing, flexographic printing, gravure printing, screenprinting, and extrusion printing may dispose the electrically-conductivematerial onto the paper layers, such as kraft paper and overlay paper,but depending on the type of paper, the electrically-conductive materialmay or may not penetrate completely through the paper.

If kraft paper (i.e., unbleached paper that is between 50-400 GSM (org/m²)) is used, and an electrically-conductive ink composition isdisposed thereon, the electrically-conductive material may penetratehalfway through the kraft paper, whereas if overlay paper (i.e.,bleached paper that is between 10-50 GSM) having less than half thebasis weight of kraft paper is used, and an electrically-conductive inkcomposition is disposed thereon, the electrically-conductive materialwill typically penetrate completely through the overlay paper. As such,in order to couple electrically-conductive material provided ondifferent layers of kraft paper together, apertures can be cut at leasthalfway through the kraft paper, so that electrically-conductivematerial disposed over a top surface of the kraft paper penetrateshalfway through the first kraft paper to form a via and establish anelectrical connection with a same type or different typeelectrically-conductive material provided on a top surface of a secondkraft paper layer underlying the first kraft paper layer. Becausedisposed electrically-conductive material may penetrate completelythrough overlay paper, it is not necessary to cut apertures in theoverlay paper to form a via and couple the electrically-conductivematerial disposed on a top surface of a first overlay paper layer to asame type or different type electrically-conductive material disposed ona top surface of a second paper layer disposed thereunder. Oncedisposed, the electrically-conductive material may be subject to thehigh pressure lamination process involving pressing at elevatedtemperature and pressure.

Electrically-conductive material, such as silver particles, may not bethe only material used to form the electrical element. For example,barium titanate (BaTiO₃) particles are used to form a dielectric of theelectrical element. To form a translucent conductor, antimony-doped tinoxide (ATO) or indium tin oxide (ITO) particles may be used. To form anelectroluminescent element, zinc sulfide (ZnS) doped with manganese,copper, a fluorescent material, or a phosphorescent material may beused.

The electrically-conductive materials described above may be disposed ina pattern over the paper layers in various embodiments of the presentdisclosure. Suitable patterns include, but are not limited to:continuous, meandering lines, spirals, circles, ovals, polyhedral shapessuch as rectangles, squares, hexagons, octagons, spirangles, sawtoothwaves, and combinations thereof. Preferably, electrically-conductivematerials may be disposed in patterns which provide a relatively largeamount of electrically-conductive material on the paper layer whilemaintaining a gap between adjacent portions of theelectrically-conductive pathway. The cross-sectional area of any linearportion of an electrically-conductive material may be important incircumstances where electrical resistance is to be minimized as thetotal electrical resistance of any electrically-conductive track is theproduct of the specific resistance per square (related tocross-sectional area) and the track length. In other words, asunderstood by those skilled in the art, greater cross-sectional areaslead to lower overall track resistances which lead to lower resistiveheating for similar electric current levels.

It may be preferable to optimize the relationship between track verticalthickness, the cross sectional area and the pitch (i.e., the distancebetween two adjacent linear portions or tracks of theelectrically-conductive material disposed on a paper layer) which shouldbe controlled to be as small as possible while ensuring that the twoadjacent linear portions do not touch. It is also important to note thatthe pressure involved in the compression steps of the high pressurelamination reduces the vertical thickness of the electrically-conductivetrack. The overall effect on total electrical resistance may vary as thecompression may increase specific resistance of theelectrically-conductive material by decreasing the cross-sectional area,while also increasing electrically-conductive contact betweenelectrically-conductive particles within the electrically-conductivematerials, thus decreasing resistance. Thus, various factors affectoverall resistance. Preferably one or more such factors are consideredin efforts to reduce overall resistance, and thus, heat generation.

The laminate in accordance with the various embodiments of the presentdisclosure may include one or more electrical contact pads which allowan electrical connection to be established to a via from the exterior ofthe laminate. In various embodiments wherein the laminate includes theelectrical element comprising same or different electrically-conductivematerials connected together, as described herein, the laminate mayinclude an electrical contact pad coupled to a via providing a site formaking an electrical connection to a first terminus of the firstelectrically-conductive material, and a second electrical contact padcoupled to a second via providing a site for making an electricalconnection to the second terminus of the second electrically-conductivematerial. In the various embodiments of the present disclosure, thelaminate may further be coupled to a component or components connectedto the electrical contact pads on the exterior of the laminate whichcomponent(s) are configured to accept AC, or pulsed DC, voltage inputfrom an electrical source such that the electrically-conductivematerial(s) are provided with a current. Such components may include,but are not limited to various receptacles for AC and DC plugs, andterminal boxes or the like for hard-wiring AC or DC inputs. Electricalcontact with the vias may also be established by coupling anyelectrically-conductive material to the electrical contact pads usingvarious structures including but not limited to metal tabs, screws,prongs, cylindrical receptacles, spring-loaded pins, etc. Additionally,methods of establishing permanent electrical contact can be establishedby affixing an external component or conductor to the electrical contactpads by soldering or the use of electrically-conductive adhesives.

A laminate's paper layers may be impregnated with resin such that thepaper layers, when stacked and compressed in the high pressurelamination, can be cured or cross-linked. The resin can be a thermosetresin such that the paper layers in a stacked relationship can becompressed and heated to cure the thermoset resin. Specific suitableresins for use in the various embodiments of the present disclosure maydiffer depending on whether the resin-impregnated paper layer is anouter protective layer (e.g., an insulating layer), or an interior corelayer (e.g., a treated kraft paper layer), or a base layer of thelaminate surfacing material (e.g., a treated kraft paper layer).Generally, resin-impregnated paper layers are impregnated with anysuitable thermoset resin including, but not limited to, acrylics,polyesters, polyurethanes, phenolics, phenol-formaldehydes,urea-formaldehydes, aminoplastics, melamines, melamine formaldehydes,diallyl-phthalates, epoxides, polyimides, cyanates, and polycyanurates,or copolymers, terpolymers or combinations thereof. Phenol-formaldehydesare generally preferred for impregnating kraft paper and acrylics ormelamine-formaldehydes are generally preferred for impregnating overlaypaper. As used in this disclosure, an insulating layer may be atranslucent layer. A translucent layer means any layer that permits atleast some light to pass there through. In other words, layers that arepartially opaque are included as translucent layers.

In some implementations, resin-impregnated paper layers which are corelayers are impregnated with a phenolic and/or epoxy resin, such as, forexample, a phenolic-formaldehyde resin. Impregnating paper layers with aresin can be carried out in any suitable manner sufficient to apply acontrolled quantity of resin to the paper, including but not limited to,screen printing, rotary screen printing, dip and squeeze, dip andscrape, reverse roll-coating, Meyer bar, curtain coating, slot-dye andgravure roller. The weight percentage of resin applied, relative to theweight of the paper layer as measured on an oven dried basis, may be inthe range of about 5 to 75%, with a preferred resin content percent(determined relative to final weight) of about 15-45%. As the resinsused in the impregnating step are normally aqueous or solvent basedsolutions, it is common in the laminating process to include a paperdrying stage to reduce the paper solvent loading. In the variousembodiments of the present disclosure, the weight percent level ofresidual solvent in the impregnated paper may be 2.5-15% with a typicallevel of about 5%. As used herein, cured can refer to both curing of athermoset resin in the sense of its irreversible setting, or thecrosslinking of other polymers with a separate cross-linker or byvarious forms of energy, or any means of fixing the resin when thelaminate surfacing material is in its compressed form such that theelectrically-conductive materials are encapsulated and will remain soduring normal operation.

Suitable papers which may be used in resin-impregnated paper layers inaccordance with the various embodiments of the present disclosureinclude but are not limited to: cellulose fiber, synthetic woven ornon-woven fiber, or/and microfiber or/and nanofiber, mixtures ofcellulose or/and synthetic fiber based papers or/and mineral fiber basedpapers or/and glass fiber based papers, coated or non-coated,pre-impregnated or non pre-impregnated that could be generally used forthe production of laminates. In various embodiments of the presentdisclosure, paper suitable for use in resin-impregnated paper layers hasat least one of the following properties: a minimum wet strength in themachine direction of 1400 cN/30 mm in accordance with the test method ofthe International Standard DIN ISO 3781, a Klemm absorbency range(capillary rise) in the machine direction of 30 to 90 mm/10 min inaccordance with the test method of the International Standard DIN ISO8787 with a preferred absorbency of 45 mm/10 min, Ash content 0 to 50%depending of the intrinsic nature of the paper used in accordance withthe test method of the International Standard Din ISO 2144, a basisweight range of 10 to 400 GSM at moisture content range of 2 to 8% inaccordance with the test method of the International Standard DIN ISO536, a pH (on hot extract) between about 4 to 9 in accordance with thetest method of the International Standard DIN ISO 6588. In variousembodiments of the present invention, papers comprising at least aportion of recycled materials may be used.

In various preferred embodiments of methods of manufacturing surfacingmaterials in accordance with the present disclosure, the high pressurelamination process may be employed. In accordance with such variouspreferred embodiments, the multiple layers, including both paper layersand layers of the electrical element according to any of the previouslydescribed embodiments are positioned in a stacked relationship betweentwo pressing plates. In such a high pressure lamination process, theplates are then pressed to a specific pressure of at least 5 MPa. Thetemperature is then raised in excess of 125° C., typically to about 140°C. The plates are then held at the elevated pressure and temperature fora period of time suitable for curing the resin. The temperature may thenbe lowered to 40° C., while maintaining the elevated pressure. Thetypical cycle time under pressure is between about 25 and about 50minutes. Upon achieving a temperature of 40° C., the pressure on theplates may then be reduced to zero gauge pressure. While it is importantto take care in ensuring that the stacked layers are aligned where anelectrically-conductive connection between adjacentelectrically-conductive materials through an aperture in an interveninglayer is to be established, the layers need not otherwise be placed inperfect edge to edge alignment, as a post-pressing trimming may becarried out to shape the final surfacing material.

While resin-impregnated layers are typically used to prepare thelaminates comprising an electrical element disposed on discrete layersof the laminate according to the disclosure, alternatively, paper layershaving pressure-sensitive adhesives thereon can be compressed with thepressure-sensitive adhesives in a facing relationship to form acomparable laminate structure. In such a process, a mask can be appliedat any locations where vias are desired in the final laminate product tofacilitate via formation, similar to the procedure described herein withreference to FIG. 3.

Other examples of electronic components that may be included in the coreof the laminate include components needed to provide current to theelectrical element. In an implementation, a power transistor serves asan amplifier for driving the electrical element in the installedlaminate. A full wave rectifier is configured to convert incoming ACpower from a power source to a DC value for use in driving theelectrical element in the installed laminate. A voltage regulator isconfigured to create a usable voltage for charging depleted batteries inan electronic component. A control circuit is configured to manage thecharging process for lithium-ion (Li-Ion) or NiMH battery chemistries,etc. in electronic components. Each of these components can be coupledto the electrical element in the laminate surfacing material anddisposed between discrete layers of the laminate surfacing material.

FIG. 1 is a schematic diagram of an example of electrically functionalsystem 100 including a laminate surfacing material 106 with an embeddedelectrical element on multiple layers integrated into a countertop 102.Other types of surfaces may also be covered with the laminate surfacingmaterial 106 (e.g., wall, door, window, piece of furniture, interior ofa vehicle, etc.). The laminate surfacing material 106 may includeelectrically-conductive material and other material described above(e.g., BaTiO₃ particles, ATO particles, ITO particles, ZnS doped withmanganese, a fluorescent material, a phosphorescent material) disposedas electrically electrically-conductive tracks or layers of theelectrical element on two or more layers of the laminate surfacingmaterial. In an implementation, the electrically-conductive material andother material described above may not be disposed throughout the entirearea covered by the laminate surfacing material (e.g., the entirecountertop 102), but rather are located in only a portion of thelaminate surfacing material, such as in a marked designated area 118.

Bubble 104 illustrates a cross-section view of an example laminateincluding the electrical element disposed on different layers of thelaminate. In an implementation, electrically-conductive material (e.g.,electrically-conductive ink) is disposed in the shape ofelectrically-conductive plates on paper layers of the substrate.Throughout this disclosure, references to electrically-conductivematerial or ink should be understood to include theelectrically-conductive material or ink itself in addition toelectrically-conductive particles left behind after theelectrically-conductive material or ink has dried.

Several layers forming the electrical element are generally illustratedin bubble 104. In the cross-section view of bubble 104, paper layer 112,optional additional paper layers 114, 116, optional decorative paperlayer 110, and insulating layer 108 are visible along the cross-section.Paper layers 112-116 illustrate two via holes through each layer.Optional decorative paper layer 110 illustrates one via hole through thelayer, and insulating layer 108 illustrates an optional via hole throughthe layer. In an implementation, electrically-conductive material andother material described above (e.g., BaTiO₃ particles, ATO particles,ITO particles, ZnS doped with manganese, a a fluorescent material,phosphorescent material) are disposed on one or more layers 108-116constituting the laminate surfacing material 106. In such across-section view, an electroluminescent element or other electricalcomponent(s) embedded in layers 108-116 of the laminate surfacingmaterial may extend linearly along the line L or may be in a directionperpendicular to the line L, in which case the layers of theelectroluminescent element or other electrical component(s) would appearshorter in the cross-section view because only the width of theelectrically-conductive track, and not the length, would be visible.

In use, the surface 102 may be equipped with an electronic component(e.g., an oscillator capable of producing a chosen resonant frequency, apower transistor to serve as an amplifier for driving theelectrically-conductive material(s), a full wave rectifier to convertincoming AC power to a DC value, a voltage regulator to create a usablevoltage for charging depleted batteries, a control circuit to manage thecharging process for lithium-ion (Li-Ion) or NiMH battery chemistries,or a power supply to provide AC, or pulsed DC, voltage) such that theelectrically-conductive material(s) are provided with a current. Theelectronic component may be electrically connected to theelectrically-conductive material(s) disposed in layers 108-116 toprovide the voltage. In at least one implementation, the electronicdevice may be physically enclosed in a structure beneath surface 102 anduser interface controls are displayed to the user via surface 102 (e.g.,LED lights embedded in surface 102, a control panel installed in surface102).

FIG. 2 shows an example of laminate surfacing material 106 having anelectroluminescent element disposed within the laminate, as shown inlaminate 200. Specifically, as shown in row 202, laminate 200 includes apaper layer 112 (e.g., kraft paper) and an insulating layer 108, asdescribed in FIG. 1, between which layers of an electroluminescentelement (i.e., electrically-conductive layers, a dielectric layer, and alight emissive layer) are disposed. The paper layer 112 may beimpregnated with resin, such as phenolic resin. The insulating layer 108may be untreated overlay (e.g., tissue paper or any suitable paper nottreated with melamine resin), treated overlay (e.g., paper treated withmelamine resin), clear plastic film, glass, film provided on adecorative paper layer, or two or more of the aforementioned stackedtogether. Layers of the electroluminescent element may be disposed byvarious methodologies, such as inkjet printing, screen printing,flexographic or gravure printing, extrusion printing, andthree-dimensional printing. The laminate 200 may also include additionalpaper layers 114, 116 (e.g., kraft paper) and a decorative paper layer110 (e.g., print sheet) as needed. The additional paper layers 114, 116may be impregnated with resin, such as phenolic resin, and thedecorative paper layer 110 may be untreated, and thus dry.

As shown in row 204, any one or more of the paper layers may include ahole or via that may be formed or cut through the entire paper layer.For example, paper layer 112 includes via holes 224, 226. Insulatinglayer 108 may include third via hole 230 depending on application. Ifthe laminate 200 requires a decorative paper layer, decorative paperlayer 110 includes via hole 228. If the laminate 200 requires additionalpaper layers, additional paper layers 114, 116 include via holes 220,222 and via holes 216, 218, respectively. The via holes described may beformed, cut through, or punched through, such as by a mechanical deviceor a laser, such that upon stacking paper layers on top of each other,when filled with electrically conductive material, the via holes arevertically aligned. For example, via holes 216, 220, and 224 arevertically aligned and via holes 218, 222, 226, 228, 230 are verticallyaligned other when paper layers in row 204 are stacked on top of eachother. As such, via holes of one paper layer may overlie via holes ofanother paper layer such that the holes are vertically aligned, so as tofacilitate via formation.

As shown in row 206, an electrically-conductive material may be disposedover paper layer 112 to form a first electrically-conductive layer 232of the electroluminescent element. In various embodiments of thelaminate 200, one or more electrically-conductive materials may bedisposed on either side or both of one or more paper layers. Theelectrically-conductive materials may be disposed in any shape, size,and may even form an outline of an aesthetic design.Electrically-conductive materials suitable for use in accordance withthe various embodiments of the laminate 200 include any material whichcan be disposed upon paper, particularly resin-impregnated paper, andwhich may be electrically electrically-conductive. Suitableelectrically-conductive materials include metals, alloys, andelectrically-conductive inks. Electrically-conductive inks arecommercially available from a number of sources and can be preparedusing a number of known methods. Particularly preferredelectrically-conductive inks suitable for use in various preferredembodiments of the present disclosure include silver and/orelectrically-conductive carbon particles. The additional paper layers114, 116 may be disposed on the side of the paper layer 112 opposite thefirst electrically-conductive layer 232 of the electroluminescentelement.

As shown in row 208, an electroluminescent material may be disposed overthe decorative paper layer 110 (if needed) to form a light emissivelayer 234 of the electroluminescent element. The electroluminescentmaterial may be zinc sulfide (ZnS) doped with manganese, copper, afluorescent material, a phosphorescent material, or any suitablematerial to form a light emissive layer of the electroluminescentelement. Alternatively, although not pictured, the electroluminescentmaterial may be disposed directly over the first electrically-conductivelayer 232 to form the light emissive layer 234 of the electroluminescentelement. If needed, the decorative paper layer 110 may be disposed overlight emissive layer 234, but because light from light emissive layer234 would then be blocked by the decorative paper layer 110, thedecorative paper layer 110 may include a cutout of the light emissivelayer 234 for light to emit through the decorative paper layer 110.

As shown in row 210, a dielectric layer (236, 238) may be disposed overboth the light emissive layer 234 and the first electrically-conductivelayer 232 of the electroluminescent element. The dielectric layer may beshown as dielectric layer 236 when the dielectric layer may be disposedover the first electrically-conductive layer 232 of theelectroluminescent element. The dielectric layer is shown as dielectriclayer 238 when the dielectric layer may be disposed over the lightemissive layer 234 that may be disposed over the decorative paper layer110. Accordingly, when the decorative paper layer 110 is stacked abovedielectric layer 236, the decorative paper layer 110 may be disposedbetween the dielectric layer 236 and the light emissive layer 234. Ineither embodiment, the dielectric layer (236, 238) may be bariumtitanate (BaTiO₃) particles, or any suitable material to form adielectric of the electroluminescent element. Alternatively, althoughnot pictured, if the electroluminescent material is disposed directlyover the first electrically-conductive layer 232 to form the lightemissive layer 234 of the electroluminescent element as described above,the dielectric layer may be disposed over the light emissive layer 234.Therefore, various embodiments of the present disclosure are not limitedto the dielectric layer (236, 238) disposed over the firstelectrically-conductive layer 232, but rather, encompass the dielectriclayer (236, 238) disposed over the light emissive layer 234.

As shown in row 212, a translucent electrically-conductive material maybe disposed over insulating layer 108 to form the secondelectrically-conductive layer 240. The translucentelectrically-conductive material suitable for use in accordance with thevarious embodiments of the laminate 200 includes any material which canbe disposed upon paper, and which may be electricallyelectrically-conductive. Suitable translucent electrically-conductivematerial includes antimony-doped tin oxide (ATO) or indium tin oxide(ITO) particles or any suitable material to form a translucent conductorof the electroluminescent element. In some embodiments, a transparentelectrically-conductive material may be used instead of the translucentelectrically-conductive material. The insulating layer 108 may notrequire third via hole 230 if the insulating layer 108 is less than halfthe basis weight of the paper layer 112 or bleached kraft paper, becausethe translucent electrically-conductive material disposed overinsulating layer 108 will penetrate through the insulating layer 108 toform the second electrically-conductive layer 240. Otherwise, if theinsulating layer 108 is not less than half the basis weight of the paperlayer 112, the insulating layer 108 will require the third via hole 230so that an electrically-conductive material that fills vias 230 and 226electrically couples the second electrically-conductive layer 240 withsecond via 226 through the insulating layer 108 after a laminationprocess. It should be understood that throughout this application viaholes are alternatively referred to as vias once conductive material isincluded therein and a lamination process that establishes electricalcontact between conductive elements is performed.

Alternatively, although not pictured, the translucentelectrically-conductive material may be disposed directly over thedielectric layer (236, 238) to form a second electrically-conductivelayer 240 of the electroluminescent element. If the translucentelectrically-conductive material is disposed directly over thedielectric layer 238 to form the second electrically-conductive layer240 of the electroluminescent element, the decorative paper layer 110that may be disposed between the second electrically-conductive layer240 and the light emissive layer 234 has a via hole 228 through thedecorative paper layer 110 that may be vertically aligned with thesecond via hole 226 of the paper layer 112. Because of via hole 228, anelectrically-conductive material that fills via holes 228 and 226electrically couples the second electrically-conductive layer 240 withsecond via 226 by traversing through the decorative paper layer 110.

Alternatively, as shown in column 214, an electrically-conductivematerial having a bus bar trace pattern may be disposed with the bus bartrace pattern over insulating layer 108 to form a bus bar 244 of theelectroluminescent element. The electrically-conductive material havingthe bus bar trace may be the same or different material as theelectrically-conductive material disposed over paper layer 112 to formthe first electrically-conductive layer 232. The translucentelectrically-conductive material may then be disposed over the bus bar244 to form an electrically-conductive layer 246. After the layersdescribed above undergo the high pressure lamination process, laminate248 may be formed, which exhibits higher conductivity than the laminate242 because of the addition of the bus bar 244. The laminates 242 and248 may be used as surfacing material in both commercial and residentialapplications, such as on furniture, kitchen countertops, table tops,store fixtures, bathroom vanity tops, cabinets, windows, doors, wallpaneling, office partitions, and other supporting substrates.

In both the laminate 242 and laminate 248, by filling the via holes 224,226 with an electrically-conductive material, after a laminationprocess, the first electrically-conductive layer 232 may be electricallycoupled to first via 224 and the second electrically-conductive layer240 may be electrically coupled to second via 226 because the first via224 makes electrical contact with the first electrically-conductivelayer 232 disposed over paper layer 112 and second via 226 makeselectrical contact with the second electrically-conductive layer 240disposed over either the dielectric layer (236, 238) or the insulatinglayer 108. The electrically-conductive material used to fill the vias224, 226 may be the same or different material as theelectrically-conductive material disposed over paper layer 112 to formthe first electrically-conductive layer 232, and theelectrically-conductive material having a bus bar trace pattern disposedover insulating layer 108 to form the bus bar 244.

In either embodiment, after a lamination process, the paper layer 112and the insulating layer 108 encapsulate the firstelectrically-conductive layer 232, the light emissive layer 234, thedielectric layer (236,238), and the second electrically-conductive layer240 within the laminate 200. Specifically, after the layers describedabove undergo a lamination process, preferably a high pressurelamination process, the resin that may be impregnated in the paper layer112 consolidates and bonds together (by heat and pressure) the firstelectrically-conductive layer 232, the light emissive layer 234, thedielectric layer (236,238), and the second electrically-conductive layer240 into a substantially continuous resin structure having significantmechanical structure, thereby forming the laminate 242, 248.

FIG. 3 illustrates an example operation 300 for forming an electricalvia, such as vias 216-230 of FIG. 2 between paper layers in a laminateusing a masking technique. A paper layer for a laminate including anelectrical element may be prepared with a sheet of untreated kraft paper314 (e.g., paper layer 112 of FIG. 2) and partially covered with aremovable mask 316 on one side of untreated paper sheet 314 at alocation of a desired electrical connection through the paper 314 atoperation 302.

A resin-treating operation 304 impregnates the kraft paper 314 with aresin to form resin-treated paper 322. The mask 316 protects a portion324 of the resin-treated kraft paper 322 during the resin-treatingoperation 304 and the portion 324 does not become impregnated with theresin. A removing operation 306 removes the mask 316, exposing theuntreated region 324 of the resin-treated kraft paper 322.

A disposing operation 308 disposes electrically-conductive material(e.g., the first electrically-conductive material 318) onto theuntreated region 324 of the resin-treated kraft paper 322. Theelectrically-conductive material saturates untreated region 324, butdoes not saturate the resin-treated region of kraft paper 314, therebyallowing for electrical conductivity through the paper 314.

FIG. 4 illustrates an example operation 400 for forming an electricalvia between layers in a laminate using a hole cutting technique. A holeforming operation 400 forms a via hole in a layer of a laminate. Forexample, hole forming operation 400 may form via holes 408, 410, 412, or414 in layers 402, 404, and 406, respectively. With reference to FIG. 2,via hole 408 may be via hole 230, via hole 410 may be via hole 228, viahole 412 may be via hole 224, and via hole 414 may be via hole 226.Layer 402 may be an insulating layer 108, layer 404 may be decorativepaper layer 110, and layer 406 may be paper layer 112. The material 416disposed on layer 402 may be, for instance, as shown in FIG. 2,translucent electrically-conductive material to form the secondelectrically-conductive layer 240, and the material 418 disposed onlayer 406 may be electrically-conductive material to form the firstelectrically-conductive layer 232. An electrically-conductive materialmay fill via hole 412, to electrically couple to material 418 after alamination process is conducted. Similarly, an electrically-conductivematerial may fill via 414, 410, and 408 to electrically couple tomaterial 416 after a lamination process is conducted. A high pressurelamination process may then apply high heat and pressure to the stack oflayers arranged in hole forming operation 400 to encapsulate thelaminate.

FIG. 5 shows a flowchart for manufacturing a laminate having anelectroluminescent element disposed within the laminate according to oneembodiment. The method 500 may be implemented, in whole or in part, bycutting, disposing and high pressure lamination process system(s),implemented by one or more processors, sensors, and/orcomputer-executable instructions stored on non-transitorycomputer-readable medium or media.

The method 500 may begin by forming at least first and second via holesthrough a first paper layer (block 502). With reference to FIG. 2, themethod 500 may form a hole or via that may be formed or cut through theentire paper layer. For example, method 500 may form via holes 224, 226through paper layer 112. Similarly, method 500 may form via hole 230through insulating layer 108 depending on application. If the laminate200 requires a decorative paper layer, method 500 may form via hole 228through decorative paper layer 110. If the laminate 200 requiresadditional paper layers, method 500 may form via holes 220, 222 and vias216, 218 on additional paper layers 114, 116, respectively. The viaholes described may be formed, cut through, or punched through, such asby a mechanical device or a laser, such that upon stacking paper layerson top of each other, the vias are vertically aligned with each other.For example, via holes 216, 220, and 224 and vias 218, 222, 226, 228,230 are vertically aligned with one another when paper layers in row 204are stacked on top of each other. As such via holes of one paper layermay be vertically aligned with via holes of another paper layer.

Method 500 proceeds by disposing a first electrically-conductive layerover the first paper layer, the first electrically-conductive layerincluding an electrically-conductive material (block 504). Withreference to FIG. 2, method 500 may dispose an electrically-conductivematerial over paper layer 112 to form a first electrically-conductivelayer 232 of the electroluminescent element. The electrically-conductivematerials may be disposed in any shape, size, and may even form anoutline of an aesthetic design. Disposing the electrically-conductivematerial may involve disposing electrically-conductive material over topof and into one or more via holes. In this step, the first via hole istypically also filled. Electrically-conductive materials suitable foruse include any material which can be disposed upon paper, particularlyresin-impregnated paper, and which may be electricallyelectrically-conductive. Suitable electrically-conductive materialsinclude metals, alloys, and electrically-conductive inks.Electrically-conductive inks are commercially available from a number ofsources and can be prepared using a number of known methods.Particularly preferred electrically-conductive inks suitable for use invarious preferred embodiments of the present disclosure include silverand/or electrically-conductive carbon particles. Method 500 may disposeadditional paper layers 114, 116 on the side of the paper layer 112opposite the first electrically-conductive layer 232 of theelectroluminescent element. Alternatively, additional paper layers 114,116 may be disposed on the same side of the paper layer 112 as the firstelectrically-conductive layer 232 of the electroluminescent element

Method 500 proceeds by disposing a dielectric layer over the firstelectrically-conductive layer (block 506). With reference to FIG. 2,method 500 may dispose dielectric layer 236 over the firstelectrically-conductive layer 232 of the electroluminescent element. Thedielectric layer 236 may be barium titanate (BaTiO₃) particles, or anysuitable material to form a dielectric of the electroluminescentelement.

Method 500 proceeds by disposing a light emissive layer over thedielectric layer, wherein the light emissive layer comprises anelectroluminescent material (block 508). With reference to FIG. 2,method 500 may dispose an electroluminescent material over thedecorative paper layer 110 (if needed) to form a light emissive layer234 of the electroluminescent element. The light emissive layer 234disposed over the decorative paper layer 110 may be disposed over thedielectric layer 236. The electroluminescent material may be zincsulfide (ZnS) doped with manganese, copper, a fluorescent material, aphosphorescent material, or any suitable material to form a lightemissive layer of the electroluminescent element

Method 500 proceeds by disposing a second electrically-conductive layerover the light emissive layer (block 510). The secondelectrically-conductive layer may include a translucentelectrically-conductive material. With reference to FIG. 2, method 500may dispose translucent electrically-conductive material over insulatinglayer 108 to form the second electrically-conductive layer 240, and theformed second electrically-conductive layer 240 may be disposed over thelight emissive layer 234. The translucent electrically-conductivematerial suitable for use in accordance with the various embodiments ofthe laminate 200 includes any material which can be disposed upon paper,and which may be electrically electrically-conductive. Suitabletranslucent electrically-conductive material includes antimony-doped tinoxide (ATO) or indium tin oxide (ITO) particles or any suitable materialto form a translucent conductor of the electroluminescent element. Insome embodiments, a transparent electrically-conductive material may beused instead of the translucent electrically-conductive material.Alternatively, method 500 may dispose translucentelectrically-conductive material directly over the dielectric layer 238to form the second electrically-conductive layer 240 of theelectroluminescent element. Disposing the transparentelectrically-conductive material may involve disposingelectrically-conductive material over top of and into one or more vias.In this step, the second via hole can be filled.

Method 500 proceeds by disposing an insulating layer over the secondelectrically-conductive layer (block 514). Lastly, method 500 proceedsby compressing the first paper layer, the first electrically-conductivelayer, the dielectric layer, the light emissive layer, the secondelectrically-conductive layer, and the filled first and second viasaccording to a lamination process, thereby electrically connecting thefirst via to the first electrically-conductive layer and the second viato the second electrically-conductive layer and encapsulating with thefirst paper layer, the first electrically-conductive layer, thedielectric layer, the light emissive layer, and the secondelectrically-conductive layer within the laminate (block 516).

By using vias, the disclosed laminate advantageously utilizes differentlayers to interconnect layers of an electroluminescent element disposedwithin the laminate 200. In addition, because the paper layer 112 andthe insulating layer 108 encapsulate the first electrically-conductivelayer 232, the light emissive layer 234, the dielectric layer (236,238),and the second electrically-conductive layer 240 within the laminate200, layers of an electroluminescent element may be protected duringusage of the laminate 200.

In addition to the advantages listed above, further advantages can berealized with additional structural modifications to the laminate 200.For instance, according to rows 206-210 described in FIG. 2, anelectrically-conductive material may be disposed over paper layer 112 toform a first electrically-conductive layer 232 of the electroluminescentelement, and the dielectric layer may be disposed directly over thefirst electrically-conductive layer 232 of the electroluminescentelement to form dielectric layer 236. Rather than disposing both theelectrically-conductive material (e.g., silver particles) and thedielectric layer (e.g., BaTiO₃ particles) onto the same paper layer 112,the electrically-conductive material may be disposed to one of theadditional paper layers (e.g., kraft paper 114 having vias 220, 222) toform the first electrically-conductive layer 232, and the paper layer112 may be treated or impregnated or saturated with a resin material andoptionally BaTiO₃ particles to serve as the dielectric. Accordingly,creators of laminate 200 would have the additional flexibility of eitherdisposing twice on the same sheet—i.e., disposing dielectric layer(e.g., BaTiO₃ particles) onto the same paper layer 112 that waspreviously disposed with the electrically-conductive material to formthe first electrically-conductive layer 232, or disposing once on onesheet and undergoing a paper impregnation process on another sheet—i.e.,disposing the electrically-conductive material to one of the additionalpaper layers (e.g., kraft paper 114 having vias 220, 222) and undergoinga paper impregnation process on the paper layer 112.

Further, in order to encapsulate the first electrically-conductive layer232, the light emissive layer 234, the dielectric layer (236,238), andthe second electrically-conductive layer 240 into a continuous resinstructure, rather than impregnating the paper layer 112 with a resinmaterial, a glue film layer impregnated with a resin material may bedisposed between untreated paper layer 112 and the insulating layer 108.Similarly, if decorative paper layer 110 is needed, the glue film layerimpregnated with a resin material may be disposed between the paperlayer 112 and the decorative paper layer 110. After undergoing the highpressure lamination process, the resin material from the glue film layercan saturate untreated paper, such as untreated paper layer 112,untreated decorative paper layer 110, and insulating layer 108, toencapsulate the first electrically-conductive layer 232, the lightemissive layer 234, the dielectric layer (236, 238), and the secondelectrically-conductive layer 240 into a continuous resin structure.

Although the laminate 200 as illustrated includes paper layer 112 andoptional paper layers 114, 116, optional decorative paper layer 110, andan insulating layer 108, it should be understood that the presentdisclosure is not limited to the precise configuration shown. Forinstance, additional paper layers may be stacked below optional paperlayer 116. Such additional paper layers may provide space for embeddingone or more electrical components to drive the electroluminescentelement disposed within the laminate structure. As another example, atreated overlay may be disposed over the second electrically-conductivelayer 240 to further protect and encapsulate the laminate 200.

As used herein, the singular terms “a” and “the” are synonymous and usedinterchangeably with “one or more” and “at least one,” unless thelanguage and/or context clearly indicates otherwise. Accordingly, forexample, reference to “a paper layer” or “the paper layer” herein or inthe appended claims can refer to a single paper layer or more than onepaper layer. Additionally, all numerical values, unless otherwisespecifically noted, are understood to be modified by the word “about.”

For simplicity and clarity of illustration, elements in the figures arenot necessarily to scale, and the same reference numbers in differentfigures denote the same elements. For clarity of the drawing, layers andelectrically-conductive materials may be shown as having generallystraight line edges and precise angular corners. However, those skilledin the art understand that the edges need not be straight lines and thecorners need not be precise angles.

Certain terminology is used in the following description for convenienceonly and is not limiting. Ordinal designations used herein and an itappended claims, such as “first”, “second”, “third”, etc., are solelyfor the purpose of distinguishing separate, multiple, similar elements(e.g., a first paper layer and a second paper layer), and do not importany specific ordering or spatial limitations unless otherwise requiredby context.

The applications and benefits of the systems, methods and techniquesdescribed herein are not limited to only the above examples. Many otherapplications and benefits are possible by using the systems, methods andtechniques described herein.

Moreover, although the foregoing text sets forth a detailed descriptionof numerous different embodiments, it should be understood that thescope of the patent is defined by the words of the claims set forth atthe end of this patent. The detailed description is to be construed asexemplary only and does not describe every possible embodiment becausedescribing every possible embodiment would be impractical, if notimpossible. Numerous alternative embodiments could be implemented, usingeither current technology or technology developed after the filing dateof this patent, which would still fall within the scope of the claims.

It will be appreciated by those skilled in the art that changes could bemade to the embodiments described above without departing from the broadinventive concept thereof. It is understood, therefore, that thisinvention is not limited to the particular embodiments disclosed, but itis intended to cover modifications within the spirit and scope of thepresent invention as defined by the appended claims.

What is claimed:
 1. A laminate having an electroluminescent element disposed within the laminate, the laminate comprising: a first paper layer; a first electrically-conductive layer comprising an electrically-conductive material, the first electrically-conductive layer being disposed over the first paper layer; a light emissive layer comprising an electroluminescent material, the light emissive layer being disposed over the first paper layer; a second electrically-conductive layer comprising a translucent electrically-conductive material, the second electrically-conductive layer being disposed over the light emissive layer; an insulating layer disposed over the second electrically-conductive layer, wherein the first paper layer and the insulating layer encapsulate the first electrically-conductive layer, the light emissive layer, and the second electrically-conductive layer within the laminate.
 2. The laminate of claim 1, wherein the first paper layer has first and second vias through the first paper layer, and wherein the first electrically-conductive layer is electrically coupled to the first via and the second electrically-conductive layer is electrically coupled to the second via, the first and second vias including an electrically-conductive material therein.
 3. The laminate of claim 1, further comprising a decorative paper layer disposed between the first electrically-conductive layer and the light emissive layer.
 4. The laminate of claim 4, wherein the insulating layer is a treated overlay.
 5. The laminate of claim 1, wherein the first paper layer is impregnated with a resin material.
 6. The laminate of claim 5, wherein the resin material comprises a phenolic resin.
 7. The laminate of claim 1, further comprising a decorative paper layer disposed between the second electrically-conductive layer and the light emissive layer.
 8. The laminate of claim 7, the decorative paper layer further comprising an aperture, the light emissive layer capable of emitting light through the aperture.
 9. The laminate of claim 8, wherein at least one glue film layer impregnated with a resin material is disposed between the first paper layer and the decorative paper layer.
 10. The laminate of claim 1, wherein the insulating layer is less than half the basis weight of the first paper layer.
 11. The laminate of claim 11, wherein the insulating layer comprises bleached kraft paper.
 12. The laminate of claim 2, wherein the second via traverses through the insulating layer.
 13. The laminate of claim 1, wherein an electrically-conductive material is patterned over the insulating layer to provide a bus bar electrically coupled to the second electrically-conductive layer.
 14. The laminate of claim 13, wherein the electrically-conductive material of the first electrically-conductive layer and the electrically-conductive material of the bus bar are the same.
 15. The laminate of claim 1, further comprising: at least a third paper layer disposed on a side of the first paper layer opposite the first electrically-conductive layer.
 16. The laminate of claim 1, wherein the first electrically-conductive layer comprises silver particles.
 17. The laminate of claim 1, wherein the electroluminescent material is a fluorescent material or a phosphorescent material.
 18. The laminate of claim 1, wherein the first electrically-conductive layer outlines an aesthetic design.
 19. A solid surface comprising the laminate according to claim 1 disposed on a supporting substrate.
 20. A method for manufacturing a laminate having an electroluminescent element disposed within the laminate, the method comprising: disposing a first electrically-conductive layer over a first paper layer, wherein the first electrically-conductive layer comprises an electrically-conductive material; disposing a light emissive layer over the first electrically-conductive layer, wherein the light emissive layer comprises an electroluminescent material; disposing a second electrically-conductive layer over the light emissive layer, wherein the second electrically-conductive layer comprises a translucent electrically-conductive material; disposing an insulating layer over the second electrically-conductive layer; and compressing the first paper layer, the first electrically-conductive layer, the light emissive layer, the second electrically-conductive layer, and the insulating layer according to a lamination process, thereby encapsulating the first electrically-conductive layer, the light emissive layer, and the second electrically-conductive layer within the first paper layer and the insulating layer to manufacture a laminate having an electroluminescent element disposed within the laminate. 